The American

124 Pages·2006·12.97 MB·English

y •
The American
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING
AND ALLIED PROCESSES, INCLUDING JOINING, BRAZING, SOLDERING, CUTTING. AND THERMAL SPRAYING
One Word Defines /
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Consult with thousands of technical experts who can help you
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Evaluate more than 300 new products to boost your productivity.
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November 13-16, 2005 F A R T F CH
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One of these welds costs
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Can you tell which one?
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The new AWS Certified Welding Supervisor program targets productivity and NEW!
how to maximize it. It will enhance your supervisors' skills, providing added AWS Certified Welding
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If you're interested in reducing welding costs and increasing January 23-28,2006
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See the AWS website for a
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For more information on the AWS Certified Welding
Supervisor program, visit our website at
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American Weiding Society
or call 1 -800-443-9353 ext 470 <m
(Outside the U.S. call 305-443-9353). ^ Founded in 1919 to advance the science, technology
and application of welding and allied processes including
Circle No. 4 on Reader Info-Card
joining, brazing, soldering, cutting and thermal spray.
©American Welding Society 2005 CER1236-1005
CONTENTS
October 2005 • Volume 84 • Number 10 AWS Web site http://www.aws.org
Features Departments
25 Brazing in Space: Enabling the Next Frontier
Washington Watchword 4
Vacuum brazing shows promise for assembling large truss
structures durina future space missions Press Time News 6
Y. Flom
Editorial 8
30 *Zeroing in on a Lead-Free Solder Database News of the Industry 10
A Web site was developed to share information regarding
lead-free solders Letters to the Editor 14
T. A. Siewert et al. Book Review 16
33 Brazing Magnesium Alloys and Magnesium Aluminum Q&A 18
Matrix Composites Brazing Q&A 19
New interest in brazing magnesium has arisen because of
the material's use in automotive and aerospace parts New Products 20
A. E. Shapiro
Coming Events 50
44 Advanced Milling Technology Helps Identify Navy Joining Center 54
Phase Transformations
Society News 55
Focused ion beam milling techniques can help lead to a
better understanding of fusion zone microstructures Tech Topics 56
M. J. Perricone
ASME Section IX 58
Guide to AWS Services 72
The American Welder
New Literature 74
Technology 76
80 Students Explore Welding in Space
Personnel 78
A group of Missouri students flew on NASA's "Weightless
Wonder" to test welding in microgravity conditions American Welder
K. Campbell
Learning Track 93
85 Tube Welding: The Foundation for Building Your Fact Sheet 96
Own Motorcycle
Welding Project 97
Help for the do-it-yourselfer who wants to learn how to
build a custom motorcycle Keep It Sale 99
Classifieds 100
91 How to Choose a Welding Glove
Tips to help you select comfortable, long-lasting Advertiser Index 102
welding gloves
J. Swearingen and J. Carter
Welding Research Supplement
149-s Estimation of Cooling Rate in the Welding of
Plates with Intermediate Thickness Welding Journal (ISSN 0043-2296) is published
A method was developed to estimate the cooling rate of monthly by the American Welding Society for
a welded section based on applying a weighting factor to S90.00 per year in the United States and posses
the Rosenthal analytical solutions for thick and thin sions, $130 per year in foreign countries: $6.00 per
single issue for AWS members and $8.00 per sin
plates
gle issue for nonmembers. American Welding So
K. Poorhaydari et al. ciety is located at 550 NW LeJeune Rd., Miami, FL
33126-5671; telephone [phone]. Periodi
156-s Particle Size Distribution of Gas Metal and cals postage paid in Miami, Fla., andadditional mail
ing offices, POSTMASTER: Send address changes
Flux Cored Arc Welding Fumes
to Welding Journal, 550 NW LeJeune Rd., Miami,
Impactor separation of welding fumes showed the FL 33126-5671.
welding process determined particle size distribution
N. T. Jenkins et al. Readers of Welding Journal may make copies of ar
ticles for personal, archival, educational or research
purposes, and which are not for sale or resale. Per
mission is granted to quote from articles, provided
customary acknowledgment of authors and
sources is made. Starred (*) items excluded from
Cover photo courtesy of NASA. copyright.
WELDING JOURNAL
WASHINGTON
BY HUGH K. WEBSTER
•;\ Aft^' WATCHWORD AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
Hexavalent Chromium Rule Enforcement" position has been created within the U.S. Depart
Moving Forward ment of Commerce. This senior staff position is intended to as
sist in U.S. efforts to combat intellectual property violations
overseas.
The Occupational Safety and Health Administration (OSHA)
It is estimated that intellectual property theft costs U.S. busi
is continuing its work toward the January 18, 2006, court-ordered
ness $250 billion annually. The coordinator will oversee the vari
deadline for issuing a final hexavalent chromium rule. In a
ous initiatives ofthe federal government, and the current admin
progress report submitted to the Third Circuit Court of Appeals
istration, with respect to international intellectual protection,
in Philadelphia, OSHA stated that it is resolving disputed issues,
and coordinate the efforts of other federal agencies.
crafting the language of the final rule, and drafting a preamble
explaining its decisions.
OSHA originally proposed to reduce the permissible expo
Congress Creates Manufacturing Caucus
sure limit for hexavalent chromium from 52 micrograms per cubic
meter to 1 microgram per cubic meter as an 8-hour time weighted
A new bipartisan "Manufacturing Caucus" has been estab
average. Hearings were held earlier this year, and many indus
lished in the U.S. Senate. A caucus in the Senate, or House, is
tries opposed these reductions.
essentially a committee composed of interested members of Con
The next progress report is due
gress who work together to fur
in early November.
ther causes related to a specific
interest. The Manufacturing
Caucus is expected to identify
U.S. House Passes Job
strategies to address the root
Safety Legislation Intellectual property theft costs causes of the problems facing
American manufacturing, and
U.S. businesses an estimated $250
The U.S. House of Representa opportunities for Congressional
tives has passed four bills that are billion annually. A new Commerce action to create and keep man
designed, according to their respec ufacturing jobs.
tive sponsors, to ease burdens on staff position will work to combat Many congressional causes
small businesses. The four bills are also establish advisory boards
as follows: these violations. consisting of industry or interest
group representatives, and it is
• (H.R. 739) The Occupational anticipated that the Manufac
Safety and Health Small Business turing Caucus will do the same.
Day in Court Act, which would give the Occupational Safety
and Health Review Commission (OSHRC) additional flexibil Small Business Drives the U.S.
ity to make exceptions when a small business misses the 15-
Economy
day deadline for filing a response to OSHA citations.
• (H.R. 740) The Occupational Safety and Health Review Com
A recent study by the U.S. Small Business Administration
mission Efficiency Act, which would increase the membership
(SBA) concludes that small businesses are the driving force be
of the OSHRC from three to five to ensure that cases are re
hind the U.S. economy. Small Business Profiles for the States and
viewed in a timely fashion.
Territories claims that small businesses create more than half of
• (H.R. 741) The Occupational Safety and Health Independent
the private non-farm gross domestic product, and create 60 to
Review of OSHA Citations Act, which would clarify that the
80% of the net new jobs. These and other data are available on
OSHRC is an independent entity that is given deference by
the SBA Office of Advocacy Web site at www.sba.gov/advo/re-
courts reviewing OSHA issues.
search /profiles.
• (H.R. 742) The Occupational Safety and Health Small Em
ployer Access to Justice Act, which would allow small employ
ers to be awarded attorneys' fees and court costs when they
Manufacturing Radio Show Begins
contest OSHA citations and prevail in court.
These bills are essentially identical to legislation passed by The National Association of Manufacturers (NAM)
the House in 2004 but then stalled in the U.S. Senate. It remains has started a weekly radio program hosted by two members of
to be seen if the Senate is any "warmer" toward them this year Congress, Sen. George Allen (R-Va.) and Rep. Albert Wynn (D-
than it was last. Md.). "Manufacturing America's Future" airs Sunday mornings
on a local Washington, D.C, station but can also be heard any
where via the NAM Web site. There are plans for national
syndication. •
New Anti-Piracy Position Established
A new "Coordinator of International Intellectual Property
Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail
[email protected]; FAX [phone].
OCTOBER 2005
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Circle No. 28 on Reader Info-Card
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'Guarantee applies to ESAB welding equipment, gas apparatus, filler metals and hand plasma machines. www.esabna.com 1-800-ESAB-123
WELJMWSI
PRESS TIME
NEWS
Chevron Begins Installation of West African Gas Pipeline Publisher Andrew Cullison
Editorial
Chevron Corp., San Ramon, Calif., recently announced West African Gas Pipeline Editor/Editorial Director Andrew Cullison
Co. Ltd. (WAPCo) has commenced installation ofthe 353-mile main offshore segment Senior Editor Maiy Ruth Johnsen
ofthe West African Gas Pipeline. Chevron, through its affiliate company, the Chevron Associate Editor Howard M. Woodward
West African Gas Pipeline Ltd., is a 38% shareholder in WAPCo. Assistant Editor Kristin Campbell
John Watson, president of Chevron International Exploration and Production, noted Peer Review Coordinator Doreen Kuhish
that when complete, the estimated $590 million project will be the first regional natural
gas transmission system to have been developed in sub-Saharan Africa. The first gas de Publisher Emeritus Jeff Weber
livery is scheduled for December 2006.
The offshore route of the 475 million cubic feet per day capacity pipeline will be par Graphics and Production
allel to the coastline, approximately 9 to 12 miles offshore in water depths of between Managing Editor Zaida Chavez
98 and 246 ft. Pipe will be laid using the lay barge, Sea Horizon, that can weld and lay Production Assistant Brenda Flores
the concrete-coated pipes at an average rate of one to two miles per day.
Advertising
Also, when the offshore section is completed, it will be connected to a new onshore
pipeline and compressor station in Nigeria, and the entire 420-mile pipeline will link National Sales Director Rob Saltzstein
the Volta River Authority's power plant at Takoradi, Ghana, to Nigerian natural gas Advertising Sales Representative Lea Ganigan Badwy
Advertising Production Frank Wilson
from an existing pipeline located near the city of Lagos.
Subscriptions
CB&I Wins Turnkey Contract for LNG Storage Project Leidy Brigman
[email protected]
CB&I has been awarded a lump-sum turnkey contract valued in excess of $100 mil
lion for the design and construction of storage tanks for a new liquefied natural gas American Welding Society
(LNG) import terminal near Port Hawkesbury on Cape Breton, Nova Scotia, Canada. 550 NW LeJeune Rd., Miami, FL 33126
Bear Head LNG Corp., a subsidiary of Anadarko Petroleum Corp. of The Woodlands, [phone] or [phone]
Tex., will own and operate the facility.
Publications, Expositions, Marketing Committee
The Bear Head LNG project is designed to meet the growing demand for natural
R. D. Smith, Chair
gas in markets in eastern Canada and the U.S. Northeast. In addition, the project in
Tlie Lincoln Electric Co.
volves the construction and operation of an approximately 7.5 million tons per annum
D. L. Doench. Vice Chair
capacity LNG terminal with a sendout capacity of 1 billion standard cubic feet per day. Hobart Brothers Co.
First gas deliveries through the Bear Head terminal are targeted for late 2008. J, D. Weber. Secretary
CB&I's work scope for the project includes the turnkey engineering, procurement, American Welding Society
and construction of two 180,000 cubic meter LNG storage tanks, including foundations, R. L. Arn, WELDiech International
insulation, paint, and piping to grade. Engineering and procurement activity for the M. C. Balmforth. Sandia National Laboratories
project is underway. T. A. Barry, Miller Electric Mfg. Co.
"The Bear Head project will be Canada's first LNG import terminal and will provide R. Durda, The Nordam Group
an important new source of clean energy," said Gerald M. Glenn, CB&I's chairman, J. R. Franklin, Sellstrom Mfg. Co.
R. G. Pali, J. P. Nissen Co.
president, and CEO.
L. Pierce, Cee Kay Supply
J. F. Saenger, lr., Consultant
Northrup Grumman Awarded Contract for Planning Work
S. Smith, Weld-Aid Products
H. Castner, Ex Off.. Edison Welding Institute
Northrop Grumman Corp., Newport News, Va., has been awarded a contract from D. C. Klingman, Ex Off, The Lincoln Electric Co.
the U.S. Navy for planning work on the nuclear-powered submarine USS Minneapolis- D. J. Kotecki. Ex Off, The Lincoln Electric Co.
St. Paul (SSN 708). The contract is valued at $5 million. L. G. Kvidahl, Ex Off.. Northrup Grumman Ship Systems
The company's Newport News sector is the prime contractor for the work, which will G. E. Lawson, Ex Off., ESAB Welding & Cutting Products
include scheduling, engineering and design work, material procurement, shop prefabri- E. D. Levert Sr., Ex Off., Lockheed Martin
E. C. Lipphardt, Ex Off., Consultant
cation, ship checks, and personnel training to support the maintenance availability.
S. Liu, Ex Off., Colorado School of Mines
The submarine is scheduled to arrive at the Newport News shipyard in October for a
R. W. Shook, Ex Off, American Welding Society
five-and-a-half-month dry-dock maintenance period.
D. R. Wilson. Ex Off., Wilson Industries
Wabtec to Overhaul Commuter Locomotives
Wabtec Corp., Wilmerding, Pa., has recently announced its MotivePower subsidiary
has signed an $8 million contract to overhaul seven commuter locomotives for the Metro-
Copyright © 2005 by American Welding Society in both printed and elec
North Commuter Railroad Co. in New York. Metro-North, the second-largest com tronic formats. The Society is not responsible for any statement made or
muter railroad in the United States, provides passenger transportation services in New opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not in
York City and its suburbs in New York, New Jersey, and Connecticut. tended for use without independent, substantiating investigation on the
The work will be performed at MotivePower's Boise, Idaho, facility. Delivery of the part of potential users.
refurbished units will begin in the first quarter of 2006.
BPA
V
OCTOBER 2005
Well, then make sure you come to the AWS Foundation Booth during the FABTECH International & AWS Welding Show,
November 13-16,2005, McCormick Place South in Chicago, Illinois, and purchase some raffle tickets. You could be
the new owner of a 2005 Trek Fuel EX 7™ Mountain Bike. For all you mountain bikers out there, here are the specs:
Frame: ZR 9000 Front Suspension: RockShox Reba SL w/Motion Control, 100mm Rear Suspension: RockShox MC 3,100mm
Wheelset: Bontrager Select Disc Crank: Bontrager Select 44/32/22 Color: Blue Rear Derailleur: Shimano Deore XT
Also, along with the bike will be a $500 gift card from Wal-Mart for any accessories you might need.
You can't come to the Show but still want to try your luck? For raffle tickets by mail, fill out the coupon below and
return it with payment. Coupons must be received by November 14 (we FedEx them to the Show for drawing
November 16). Or you can go online at www.aws.org and purchase tickets with your charge card.
The AWS Foundation was established by the American Welding Society in 1989 to enhance the research and
education opportunities in welding and related industries. All proceeds received from this raffle will go towards
scholarships to help students in the welding industry achieve their career goals in welding technology, welding
engineering, to become scientists, teachers, trained technicians, and welders.
Foundation, Inc.
TREK and Wal-Mart are not endorsing, sponsoring, or otherwise affiliated with this promotion.
Taxes and shipment from Chicago are the responsibility of the winner. Building Welding's Future through Education
Circle No. 7 on Reader Info-Card
ENTER TO WIN A 2005 TREK FUEL EX 7™ MOUNTAIN BIKE
NAME. COMPANY.
ADDRESS
CITY_ STATE ZIP.
DAYTIME PHONE. . EVENING PH0NE_
. TICKETS @ $3 EACH TICKETS @ 3 FOR $6 J1CKETS@5F0R$10
• CHECK ENCLOSED (MAKE PAYABLE TO AWS FOUNDATION, INC.) AMOUNT
• CREDIT CARD PAYMENT: (CIRCLE ONE) VISA MASTERCARD AMERICAN EXPRESS
CARD#. EXPIRATION DATE
SIGNATURE.
MAIL TO: AWS FOUNDATION, INC., 550 NW LEJEUNE ROAD, MIAMI, FL 33126 Participants need not be present to win.
EDITORIAL American Welding Society
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Let's Win the Race Officers
President Damian J. Kotecki
The Lincoln Electric Co.
Vice President Gerald D. Uttrachi
"Human history becomes more and more a race between education WA Technology. LLC
and catastrophe." — H. G. Wells (1866-1946) Vice President Gene E. Lawson
ESAB Welding & Cutting Products
This is a somewhat ominous statement from this Victorian novelist, journalist, and
Vice President Victor Y. Matthews
historian. Wells made his debut with The Time Machine (1895), followed by The Invisi
The Lincoln Electric Co.
ble Man (1897) and The War of the Worlds (1898). He also published several nonfiction
works on world organization and mankind's prospects for the future. He had a passion Treasurer Earl C. Lipphardt
ate concern for society and education. Even though decades have passed since his work
Consultant
was first published and this observation made, it still holds true today. Education is a
key element for progress and humanity's technological development. Executive Director Ray W Shook
Do you realize that the welding industry may soon be facing an employment catas American Welding Society
trophe? Take a look at the following statistics.
• Currently there are more than 600,000 welding professionals working in the United
Directors
States.
• The U.S. Bureau of Labor Statistics predicts a shortage of 250,000 welding profes T. R. Alberts (Dist. 4). New River Community College
sionals by the year 2010. B. P. Albrecht (At Large). Miller Electric Mfg. Co.
• The average age of welders in today's workforce is 54.
0. Al-Erhayem (At Large). JOM
• Many of these people will retire within the next ten years.
• U.S. industries report difficulties locating qualified individuals. A. J. Badeaux, Sr. (Dist. 3). Charles Cty. Career & Tech. Center
• Welding and joining have been identified as the "industry of the future" by the U.S. K. S. Baucher (Dist. 22), Technicon Engineering Sendees, Inc.
Department of Energy. J. C, Bruskotter (Dist. 9). Bruskotter Consulting Services
• Advanced technology is creating more uses for welding in the workplace and expand
C. F. Burg (Dist. 16), Ames Laboratory IPRT
ing employment opportunities.
• Industrial manufacturing is at its highest level in 20 years, and new orders are at their N. M. Carlson (Dist. 20). Idaho National Laboratory
highest since 1950 (U.S. Dept. of Commerce, Manufacturing in America, January H. R. Castner (At Large). Edison Welding Institute
2004).
N. A. Chapman (Dist. 6). Entergy Nuclear Northeast
The welding professionals mentioned above include key people and positions, in
S. C. Chappie (At Large). Consultant
cluding engineers, welders, technicians, inspectors, researchers, sales personnel, and
educators. N. C. Cole (At Large). NCC Engineering
The AWS Foundation's sole purpose and vision is to attract people to the welding J. D. Compton (Dist. 21). College ofthe Canyons
industry by providing funding for education, research, and training. It meets the needs
L P. Connor (Dist. 5), Consultant
for education and research in the field of welding and related joining technologies.
J. E. Greer (Past President). Moraine Valley C. C
How does it do this? By identifying and providing financial support for
• Welding research (fellowships) M. V. Harris (Dist. 15), Reynolds Welding Supply
• Welding engineering (university scholarships) R. A. Harris (Dist. 10), Penton Publishing Co.
• Technicians (junior college scholarships)
W. E. Honey (Dist. 8), Anchor Research Corp.
• Welders (training school support)
Will you help us? You can assist by supporting the Foundation's efforts through your D. C. Howard (Dist. 7). Concurrent Technologies Corp.
contributions of cash, by setting up a trust, through estate bequests, gift annuities, and J, L Hunter (Dist. 13). Mitsubishi Motor Mfg. of America. Inc.
gifts of stocks or properties. You will be giving back to your industry, making it stronger J. L. Mendoza (Dist. 18), City Public Senice
through education and helping us win the race between education and catastrophe.
S. P. Moran (Dist. 12), Miller Electric Mfg. Co.
T. M. Mustaleski (Past President), BWXTY-12. LLC
R. L. Norris (Dist. l).Meniam Graves Corp.
Scholarships Awarded in
T. C Parker (Dist. 14), Miller Electric Mfg. Co.
2004-2005
0. P, Reich (Dist. 17). Texas State Technical College at Waco
•18 National Named W, A. Rice (At Large). OKI Bering, Inc.
Scholarships ($46,500)
E. Siradakis (Dist. ll). Aiigas Great Lakes
•136 District Scholarships
($110,000) K. R. Stockton (Dist. 2). PSE&G, Maplewood Testing Sen*.
•6 Fellowships ($150,000) P. F. Zammit (Dist. 19), Brooklyn Iron Works. Inc.
Ronald C. Pierce
Chair, A WS Foundation Board of Trustees
OCTOBER 2005